Reinforcement devices, systems and methods for constructing and reinforcing the foundation of a structure

ABSTRACT

The present disclosure relates to reinforcement devices, systems and methods for use in constructing new structures, including post frame structures. Specifically, the present disclosure relates to reinforcement devices, systems and methods for replacing traditional wood and/or precast concrete columns utilized in building a new construction foundation, with a height adjustable foundation column assembly constructed from a corrosion resistant material. The present disclosure also relates to reinforcement devices, systems and methods useful for reinforcing existing post frame structures, particularly those with framing elements requiring repair.

This application is a continuation of U.S. Ser. No. 16/200,973 filed onNov. 27, 2018, which is a continuation-in-part of U.S. Ser. No.15/720,157 filed on Sep. 29, 2017, which claims priority to U.S.Provisional Application Ser. No. 62/401,381 filed Sep. 29, 2016, whichis incorporated in its entirety herein.

TECHNICAL FIELD

The present invention relates to reinforcement devices, systems andmethods useful for constructing and reinforcing a structure.Specifically, one embodiment of the reinforcement device is anadjustable foundation system for use as reinforcement structuralcolumns, posts and/or supports for a structure, particularly for use innew construction of pole barns and other buildings. The presentinvention further includes a reinforcement device useful for securing toand stabilizing existing structural posts of a building such as woodensupport columns of a post frame or pole buildings. The present inventionalso relates to a system and method for raising the height of anexisting building or structure using a reinforcement device, therebyproviding more useful interior space for accommodating large pieces ofequipment and/or for providing more storage capacity.

BACKGROUND

It is, of course, generally known to construct a structure, such as ashed, barn, garage, etc., using wooden posts set into a series of holesdug in the ground to define a perimeter and create the initial frame forthe structure. In the case of pole barns, the structural or framingposts are buried in the ground, and often surrounded by dirt, gravel orconcrete. However, long-term contact of wooden posts with the ground canlead to post rot of these wood pilings, resulting in potentialstructural failure, often prematurely. Additionally, many olderstructures, such as older barns, with wood columns embedded into theground subject to decay, rotting, and insect infestation, which canaffect the overall integrity of the structure. However, it is oftendesirable to repair older, wood frame structures to maintain theirintegrity for various reasons including costs, convenience and history.

Improvements continue to be made to provide longevity, durability andstrength to post frame buildings. The traditional method of repairrequires that large holes be excavated within the building next toand/or around each post. A new post is then installed next to theexisting post and the posts are bolted together. With this traditionalmethod, there is typically no new foundation installed and no additionaluplift protection. Opening up large holes including breaking and tearingout concrete flooring around the existing columns is invasive, laborintensive and costly. Additionally, most traditional repairs will takeseveral days to a week to complete, and can be expensive.

For decades, post frame buildings were built all across America thatwere designed to store equipment and machinery that was much smaller instature than what is in use on today's modern farms. As a result, manyof these otherwise useful buildings are being removed to make room fornew buildings with higher interior clearances to accommodate today'slarger farm machinery. However, razing a structure and building a newone can be time-consuming and expensive. Additionally, many olderstructures have value, not only historically but may also havesentimental value to the owner. Therefore, a need exists forrefurbishing existing buildings by extending existing wood columns toincrease the interior space clearance, thereby providing the interiorheight and space needed for today's modern farm equipment.

Additionally, there exists a need for options to the traditional woodpost construction of foundations for new buildings. Replacingtraditional wood foundations with easy to use columns made of materialable to withstand rot, decay and insect damage that traditional woodenposts are susceptible to, or expand and contract due to freezing andthawing, results in a structure more durable and well-protected againstdestructive natural forces than the average post frame buildingfoundation. Because each column can be stabilized and adjusted bothvertically and horizontally the integrated grade board bracket allowsthe wall post to interlock. This allows the entire foundation system tobe stabilized and minor, if any, post movement occurs when backfillingthe excavated holes with concrete, resulting in a solid, precisefoundation system. Moreover, the lack of pre-cast concrete postseliminates the possibility of blow outs that can compromise theintegrity of the foundation's concrete.

A need, therefore, exists for improved devices, systems and methods forreinforcing a structure. Specifically, a need exists for improveddevices, systems and methods for reinforcing and stabilizing failingstructural elements including structural and framing posts quickly andeasily.

A need further exists for improved devices, systems and methods forproviding a reinforcement device for use in constructing an improvedfoundation for a structure wherein the foundation is resistant to theelements, rot and decay and insect infestation.

Additionally, a need exists for improved devices, systems and methodsfor constructing a foundation using preassembled columns, and thepre-drilled holes which make for simple attachment to boards and planksused in the construction of a foundation for a structure. This savestime and increases labor efficiency.

A need further exists for improved devices, systems and methods forconstructing a foundation utilizing columns much lighter thantraditional wooden posts or precast concrete columns, making liftingsafer and easier for the worker and reducing the need for heavymachinery to assist in transportation and installation.

Further, a need exists for improved devices, systems and methods forproviding a reinforcement device useful in raising the height of anexisting structure.

Moreover, a need exists for improved devices, systems and methods forreinforcing wooden posts or columns of an existing structure using fewertools and workers to install the device.

A need further exists for improved devices, systems and methods forproviding an efficient and time-saving structurally sound repair tofailing columns supporting a building.

Additionally, a need exists for improved devices, systems and methodsfor constructing a new structure while further protecting it from futuredecay and potential insect infestation.

A need further exists for improved devices, systems and methodsreinforcing and stabilizing a structure utilizing a multi-sided sleevedevice for surrounding and reinforcing an existing structural woodenpost.

A need further exists for improved devices, systems and methods forstabilizing a structure and providing additional uplift and lateralstrength to increase the height of an existing structure therebyincreasing the useful interior space of the structure. Often minorheight loss is due to sagging from the breakdown of wood columns andsettlement.

Additionally, a need exists for repairing and or straightening saggingwalls, and providing improved structural integrity to an existingstructure so it can better withstand damage from storms, includingpotential wind damage.

Moreover a need exists for improved devices and systems adaptable forreinforcing a structural element, such as a post for a pole building,have a variety of shapes and sizes.

Further, a need exists for improved devices, systems and methods for astructurally sound repair of existing structural columns at a fractionof the cost to replace existing structural elements or even an entirestructure.

SUMMARY

The present disclosure relates to reinforcement devices, systems andmethods for use in constructing new structures, and repairing post framestructures. Specifically, the present disclosure relates to foundationsystems, reinforcement devices, systems and methods for replacingtraditional wood and/or precast concrete posts traditionally utilized inconstructing or repairing existing post frame foundation components. Thepresent disclosure provides a height adjustable foundation column foruse in constructing a foundation for new construction. The heightadjustable foundation column assembly is ideally constructed fromcorrosion resistant materials.

In one exemplary embodiment, the present disclosure relates to areinforcement device for constructing and supporting a foundation for astructure, the device comprising a column body having a top and abottom, a bracket secured to the top of the column body, a heightadjustment mechanism positioned above and passing through the bracketand within an interior space of the column body extending from top tobottom, the adjustment mechanism capable of vertically moving the columnbody and bracket between any desired height, and, a stabilizer padsecured to an end of the height adjustment mechanism opposing the top ofthe column body.

In another embodiment, the present disclosure relates to a heightadjustable assembly for constructing and supporting a foundation for astructure. The assembly comprises a column body having a top, a bottomand an interior space, at least one upright arm secured to a horizontalbase at the top of the column body, a height adjustment mechanismincluding: a rod passing through an opening in the base, a hollowcylinder extending vertically and separated from an undersurface of thebase, and, an extension rod extending upward through the interior spaceof the column body and into an interior of the cylinder, wherein the rodenters the interior of the cylinder for engagement with the extensionrod to vertically move the column body and bracket between any desiredheight.

In yet another embodiment, the present disclosure relates to a methodfor creating a foundation for a structure. The method includes the stepsof outlining a perimeter of a structure through the excavation of aplurality of holes, providing a height adjustable column assemblycomprising, a column body having a top and a bottom, a bracket securedto the top of the column body, a height adjustment mechanism extendingabove and downward through the bracket within an interior space of thecolumn body, the height adjustment mechanism capable of verticallymoving the column body and bracket between any desired height; and, astabilizer pad secured to an end of the height adjustment mechanismopposite the top of the column body, positioning each height adjustablecolumn assembly within each hole forming the perimeter, wherein thebracket is above ground level and the stabilizer pad is positioned atthe bottom of the hole, adjusting each height adjustable column assemblythrough the height adjustment mechanism to an acceptable level position;and, disposing at least one board on each of the brackets, forming aninitial foundation for the structure.

In another exemplary embodiment, the present disclosure relates to areinforcement device useful for securing to and stabilizing existingstructural posts of a building such as wooden support columns of a postframe or pole buildings. The reinforcement device has a multi-sidedcorrugated structure, which is adaptable for engagement with structuralposts having a variety of shapes and sizes. Additionally, the presentdisclosure relates to a system and method for increasing the height ofan existing structure, due to sagging from a breakdown of wood columnsand settlement, or increasing the height of the entire structure,thereby increasing the useable interior clearance space to accommodatelarge pieces of equipment.

To this end, in an embodiment of the present invention, a device forreinforcing an existing structural element of a building is provided.The device comprises a multi-sided sleeve having an elongated bodycomprising a longitudinal center section integrally connected alongopposing edges to a pair of opposing longitudinal legs or panels havinga length the same as the center section. Each leg is connected at anangle or bend to the center section, wherein the angle can varydepending on the size of the structural element.

In an embodiment, a reinforcement device is provided for use inreinforcing an existing structural column. The reinforcement devicecomprises a multi-sided structure, having a center longitudinal sectionflanked on either side and integrally connected to a pair of opposinglegs, wherein the legs have the same longitudinal length as the centersection. Each of the center section and legs further include a raisedportion or apex substantially in the middle of the center section andeach leg, wherein the raised portions provide an overall corrugatedstructure to the device and intermittent contact with the column.

In another embodiment of the present invention, a system and method forincreasing the height and interior space of an existing structure isprovided. The system and method includes the steps of providing ansuitable reinforcement device, creating a space around an existingcolumn or post, placing the reinforcement device around the existingcolumn, driving the reinforcement device below grade to the originalfoundation pad, cutting the existing column and supporting it with thereinforcement device, and lifting the structure to the desired height.Once this is achieved a wood spacer block can be installed between thesevered column to direct the load back to the original foundation.Fasteners are installed to adjoin the pieces together.

It is, therefore, an advantage and objective of the present disclosureto provide a reinforcement device, system and method useful for creatinga foundation for a structure that is resistant to temperature changes,decay, and insect infestation.

It is, therefore, an advantage and objective of the present disclosureto provide a reinforcement device, system and method for reinforcing andstabilizing existing structural elements of a building includingstructural and framing posts, quickly and easily.

It is further an advantage and objective of the present disclosureprovide an improved reinforcement device, system and method forstabilizing a structure and providing reinforcement to existingfoundation columns and uplift strength to increase the height of anexisting structure thereby increasing the useful interior space of thestructure or to lift to correct any sagging resulting from failing woodcolumns.

Additional features and advantages of the present invention aredescribed in, and will be apparent from, the detailed description of thepresently preferred embodiments and from the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord withthe present concepts, by way of example only, not by way of limitations.In the figures, like reference numerals refer to the same or similarelements.

FIG. 1 illustrates a perspective view of a post frame structureincorporating an embodiment of a reinforcement device, particularly aheight adjustable column assembly according to the present disclosure;

FIG. 2 illustrates a perspective view of the height adjustable columnassembly in use with a post frame structure according to the presentdisclosure;

FIG. 3 illustrates an embodiment of the height adjustable columnassembly according to the present disclosure;

FIG. 4 illustrates an embodiment of the height adjustable columnassembly according to the present disclosure supporting a board for astructure;

FIG. 4a illustrates a perspective view of an embodiment of a heightadjustable column assembly according to the present disclosure;

FIG. 4b illustrates a perspective view of an embodiment of a heightadjustable column assembly for use as a corner support according to thepresent disclosure;

FIG. 4c illustrates a perspective view of the embodiment of a heightadjustable column assembly for use as a corner support according to thepresent disclosure;

FIG. 4d illustrates a perspective view of an embodiment of a heightadjustable column assembly incorporating another embodiment of a heightadjustable mechanism;

FIG. 5 illustrates an embodiment of a height adjustable column assemblyaccording to the present disclosure, incorporating an alternativeembodiment of a height adjustment mechanism;

FIG. 6 illustrates the embodiment of the height adjustable columnassembly according to the present disclosure, incorporating thealternative embodiment of the height adjustment mechanism in FIG. 5;

FIG. 7 illustrates a close-up view of the height adjustment mechanismused in the height adjustable column assembly of FIGS. 5 and 6;

FIG. 8 illustrates a perspective view of a height adjustable columnassembly according to the present disclosure, incorporating anotheralternative embodiment of a height adjustment mechanism;

FIG. 9 illustrates a perspective view of the height adjustable columnassembly of FIG. 8, incorporating the alternative height adjustmentmechanism;

FIG. 10 illustrates a perspective view of the height adjustable columnassembly of FIG. 8, incorporating the alternative height adjustmentmechanism;

FIG. 11 illustrates an embodiment of an alternative bracket useful forcreating the foundation of a structure;

FIG. 12 illustrates a grade board engaged with the bracket of FIG. 11;

FIG. 13 illustrates another embodiment of the combination grade boardand alternative bracket useful for creating a foundation of a structureusing the height adjustable assembly of the present disclosure;

FIG. 14 illustrates an interior view of a post frame structureincorporating an embodiment of a reinforcement device, particularly areinforcement sleeve according to the present disclosure;

FIG. 15 illustrates a perspective view of an embodiment of areinforcement sleeve according to the present disclosure;

FIG. 15a illustrates a close-up of an uplift tab found on thereinforcement sleeve shown in FIG. 15;

FIG. 15b illustrates a perspective view of an embodiment of areinforcement sleeve according to the present disclosure;

FIG. 16 illustrates the reinforcement sleeve according to the presentdisclosure positioned around a target column; and,

FIG. 17 illustrates an interior view of a post frame structureincorporating an embodiment of a reinforcement sleeve according to thepresent disclosure.

DETAILED DESCRIPTION

The present disclosure relates to devices, systems and methods forconstructing a foundation and replacing the traditional wood and/orprecast concrete columns used for supporting a structure, such as apost-frame building. Specifically, the present disclosure relates toimproved reinforcement devices, systems and methods useful in theconstruction of solid, corrosion-resistant foundations for newbuildings, including pole or post-frame buildings. The presentdisclosure also relates to another embodiment of improved reinforcementdevices, systems and methods useful for reinforcing and stabilizingexisting structural posts of a building, such as existing wooden columnsof a post frame or pole buildings. Additionally, the present disclosurerelates to a system and method for utilizing a reinforcement device forincreasing the height of an existing structure, thereby increasing theuseful interior space of a structure to accommodate larger pieces ofequipment and machinery and/or to provide additional storage capacity.

Now referring to the figures, wherein like numerals refer to like parts,FIGS. 1-4 a-4 d illustrate an embodiment of a reinforcement device 100,specifically, a height adjustable column assembly having a heightadjustment mechanism therein. FIGS. 5-10 illustrate additionalembodiments of a reinforcement device 300, 400, specifically a heightadjustable column assembly using alternative versions of a heightadjustment mechanism, respectively. FIGS. 11-13 illustrate a bracket andgrade board combination useful in constructing the foundation for astructure. FIGS. 14-16 illustrate a reinforcement device, specifically areinforcement sleeve useful for stabilizing and strengthening existingcolumns and/or posts of existing building structures, such as pole barnsconstructed from wooden posts. FIG. 17 illustrates an embodiment of thereinforcement device used for lifting an existing structure andincreasing the interior space of the structure.

Creating a foundation for a structure, particularly a post-frame or polebarn structure 500, that is resistant to changing weather conditions,rot or decay, and insect-infestation, is vital for the long-termsurvival of the structure. Additionally, having options away fromtraditional wood and precast concrete as foundation supports isdesirable to meet many of these requirements, and potentially reducelabor and equipment requirements and associated costs. As shown in FIGS.1-3 and 4 a-4 d, an embodiment of a reinforcement device in the form ofa height adjustable column assembly 100 incorporating an embodiment of aheight adjustment mechanism 130 is provided for use in the constructionof a structure 500. Alternative embodiments of height adjustmentmechanisms 300, 400 incorporated into the height adjustable columnassembly 100 are shown in FIGS. 5-10.

The height adjustable column assembly 100 includes a column body 102having a top 104 and a bottom 106, a bracket 120, 128 at the top of thecolumn body and a height adjustment mechanism 130. As shown in FIG. 2,when used as a foundation column for a structure 500, the column body102 of the height adjustable column assembly 100 is placed within a hole600 excavated in the ground 610 using known techniques to form theperimeter of the foundation 520 for a building structure 500. Thebracket 120, 128 of the column assembly 100 remains at or slightly aboveground level 610 for receiving and securing boards 505, also known asplanks, grade boards or splashboards, which are secured to the heightadjustable column assemblies to create the foundation 520 ultimatelysupporting the entire structure 500.

As shown in FIGS. 3, 4 and 4 a-4 d, the column body 102 of the presentheight adjustable column assembly 100 is generally a cage formed from aplurality of reinforcing vertical bars 112, also referred to as “rebar,”which form an outer perimeter of the cage of the column body 102, and aninterior space 102 a of the column body. For example, in one embodimentshown in FIGS. 4a and 4b , four, evenly-spaced vertical bars 112 form agenerally rectangular cage of the column 102. The top end 112 a of thevertical bars 112 are welded directly to the underside or undersurface124 a of the base 124 of the bracket 120, 128 (FIG. 4c , FIG. 5 and FIG.8). The opposing bottom end 112 b of the vertical bars is securedtypically by welding to a reinforcement anchor 114 at the bottom 106 ofthe column body 102 (FIG. 4a ). It should be understood that althoughfour vertical bars 112 are shown, any number of vertical bars may beused to create the cage structure of the column body 102.

The column body 102 is further strengthened and stabilized by at leastone reinforcement anchor 114, which horizontally spans the interiorspace 102 a inside the perimeter of the cage. The reinforcement anchor114 has generally an X-shape, where each leg 114 a of the anchor isrigidly connected, such as by welding, to each of the vertical bars 112.Alternatively, the individual vertical bars 112 of the column body 102may engage openings 114 b in the legs 114 a of the anchor, where thebars can be secured, also by welding (FIGS. 4a -4 d, 5, 6, 8 and 9). Thereinforcement anchor 114 further includes a center opening 114 c forreceiving components of the height adjustment mechanism, for example,the guide tube or cylinder 134, and the extension rod 135 (FIGS. 4a and8). The reinforcement anchor 114 acts as a brace providing additionalstrength to vertical bars 112 forming the column body 102 and stabilizesthe components of the height adjustment mechanism 130 within theinterior of the column body. The reinforcement anchors 114 assist tomaintain the integrity of the column body 102 and height adjustmentmechanism 130 components as the column body is surrounded by dirt,gravel or concrete after the column assembly 100 is placed in the groundand initially leveled. Although the figures illustrate embodiments withvarying numbers of reinforcement anchors 114 positioned in a number ofdifferent locations within the column body 102, it should be understoodthat any number of reinforcement anchors 114 may be incorporated, aswell as positioned at various points within the column body 102,including at or near the bottom 106 of the column body, and in anylocation between the bottom and the bracket 120.

The top 104 of the column body 102 includes a bracket 120, 128. Thebracket 120, 128 is designed to receive and secure boards 505, such asthe splashboards, grade boards or planks to create the foundation 520 ofa building 500, as well as, receive and secure vertical columns 510 usedfor constructing the walls of the building (FIGS. 3 and 4). As shown indetail in FIGS. 4a and 4b , there are at least two embodiments for thebrackets 120, 128, depending on whether the bracket is a corner bracket120, or a side bracket 128. The corner bracket 120 includes at least oneupright arm 122 connected to a horizontal plate forming a base 124 (FIG.4b ). The side bracket 128 includes two opposing upright arms 122connected by the base 124, essentially forming a U-shape or H-shapebracket (FIG. 4a ). Lower sections 122 a of the arms 122 are connected,generally by welding, to the vertical bars 112 forming the column body102, while upper sections 122 b of the arms include a plurality of holes121 for receiving fastening devices for securing the boards and verticalcolumns placed between the opposing arms.

Each upright arm 122 further includes a notch 122 c on an outer edge ofthe upper section 122 b of each arm, the notch adapted for receiving,squaring and levelling a string (not shown) useful in determining theoverall squareness and level position of a plurality of the columnassemblies 100 after placement of the assemblies in respective holes 600forming the initial perimeter of the building 500 (FIG. 2). Thedesignated use of the height adjustable column assembly 100, as either aside wall column 128 (FIG. 4a ) for use in the construction of a longside of the proposed building, or as a corner column 120 (FIG. 4b ) foruse in the joining of a corner of the propose building, dictates whichembodiment of the bracket 120, 128 is needed.

As shown in FIGS. 4a and 4b , the bracket 128 includes a vertical plate125 extending downward from the base. The vertical plate 125 furtherextends and connects between a lower section 122 a of the opposing arms122 (FIG. 4a ). At least one integrated side support bracket 126 isdisposed on the vertical plate 125 at the base of the bracket.Optionally, two side support brackets 126 arranged, one on eachperpendicular connecting side of the base 124 of the bracket, are usedfor corner placement of boards on the corner bracket 120 (FIGS. 4b and4c ). The side support bracket 126 is designed to receive a board 505,grade board, splash board or plank, which is used to build thefoundation 520 of the building (FIGS. 3, 4 and 4 c). Side supportbracket 126 may include a vertical centerline in the form of a slot 126a used for accurate measurement of column spacing (typically about 8feet apart) allowing precise placement of building columns when settingout the perimeter of the building 500 (FIGS. 4a, 4b ).

During construction of a new building, after multiple adjustable columnassemblies 100 are placed in each of the respective excavated holes 600around the proposed perimeter of a building, the side support bracket126 or brackets of each column assembly 100 engage a board 505, spanningacross each of the assemblies (FIG. 4) to begin building the foundation520. The column assemblies 100 are leveled through placement of aleveling string (not shown) along each notch 122 c on the outer edge ofeach upright arm 122. A laser level (not shown) is used in conjunctionwith the leveling string after it is placed in the notch 122 c to assistin accurately leveling each of the column assemblies 100 afterplacement. Because each grade board 505 interlocks within the sidesupport bracket 126 of the column assembly 100 thereby providing lateralsupport, the entire foundation system is stabilized and no post movementoccurs when installing structural columns 510 for ultimately supportingtrusses 512 of the structure 500 (FIG. 1). The combination of the sidesupport brackets 126 with the grade boards 505 keeps each of columnassemblies 100 in position in the excavated hole 600 before the hole isfilled with concrete and secured.

FIG. 4 illustrates one embodiment of a height adjustment mechanism 130for use in the height adjustable column assembly 100. In thisembodiment, the height adjustment mechanism 130 is a three componentassembly, including: a rod 132; a hollow guide tube or cylinder 134disposed vertically from and connected to an undersurface 124 a of thebase 124 of the bracket 120, 128; and an extension rod 135. The rod 132may have a threaded outer surface 132 a (FIGS. 4a-c ). Optionally inanother embodiment, the rod 133 may have a smooth outer surface 133 awithout threading (FIG. 4d ). The rod 132 passes through a centralopening 124 b in the base 124 of the bracket 120, 128, entering into theinterior space of the guide tube or cylinder 134, which is positioned inline with the opening in the base. The guide tube 134 can have anylength, but it is typically about one third to one half the length ofthe column body 102. The guide tube or cylinder 134 includes a threadednut (not shown, but see reference number 403 in FIG. 8) welded at thetop of the guide tube where the tube connects to the undersurface 124 aof the base 124 of the bracket 120, 128. As the rod 132 passes throughthe opening 124 b in the base, the threaded outer surface 132 a of therod 132 engages with the threaded nut on the top end of the guide tube134. Optionally, in another embodiment, rather than a threaded nut atthe top of the cylinder 134, the interior surface of the guide tube 134itself is threaded for engagement with the threaded surface 132 a of thefirst rod 132. In yet another embodiment, the rod 133 has a smooth,non-threaded outer surface 133 a, and guide tube 134, without either thethreaded nut or a threaded inner surface, simply telescope together forengagement with the second extension rod 135 (FIG. 4d ).

The third component of height adjustment mechanism 130, the extensionrod 135, is generally a smooth rod having a diameter smaller than thatof the guide tube 134, that is positioned upward through the bottom 106of the column body 102 and into the interior of the guide tube 134. Theextension rod 135 includes disk-shaped base or foot plate 136 at thebottom of the rod and outside of the column body 102 (FIG. 4). Theextension rod 135 further passes through a center opening 114 c of atleast one reinforcement anchor 114, which assists in stabilizing andholding the extension rod in position. The foot plate 136 may be flat orinclude an angled bottom, which is configured to engage the floor of anexcavated hole, thereby providing resistance when the height adjustmentmechanism 130 is engaged to vertically move the column assembly 100.

The present height adjustment mechanism 130 is an improvement and anadvantage over other mechanisms in standard foundation columns becauseit provides the option to adjust the adjustable column assembly 100 on aconstruction site, with precision, while the assembly is in an uprightposition and already placed within an excavated hole 600. Rough heightadjustments can be made prior to installation of the adjustable columnassembly 100 into the excavated hole 600; however final, finessedadjustments can be made through the height adjustment mechanism 130,even after wet cement is added to the hole.

Specifically, operation of the present height adjustment mechanism 130includes the rod 132 passing through the opening 124 b in the base 124of the respective bracket 120, 128 for engagement with the guide tube134, either through the threaded nut disposed at the top of the guidetube, or through engagement with a threaded interior surface of theguide tube, or, optionally, through non-threaded telescoping engagementbetween the rod and the guide tube. In one example, using an appropriatetool, such as a screw gun, the rod 132 is rotated downward into thethreaded nut 134 a of the guide tube 134 until it engages with theextension rod 135, which is positioned upward into the interior space ofthe guide tube 134. By rotating or pushing the rod 132 downward into theguide tube, and against the extension rod 135, the column assembly 100can be precisely adjusted, up or down, after placement of the columnassembly into the excavated hole 600. Because the guide tube 134surrounds and protects the rod 132 and extension rod 135 as they connectinside the guide tube from contact with dirt or cement as it is placedwithin the hole 600 around the column assembly 100, the heightadjustment mechanism 130 can adjust the height of the column assemblyeven after concrete is poured within the hole and while still wet. Afterthe appropriate adjustments are complete, the rod 132 can then either beremoved or cut, and a vertical column 510 for construction of astructure can be secured in the bracket 120 using known fasteners (FIG.3). Thus, the height adjustment mechanism 130 is useful to accommodatepost holes of inconsistent depths and levels, because it permits custom,on-site levelling of the foundation boards 505, even after surroundingthe column assembly with dirt, gravel, concrete or any other securingmaterial.

FIGS. 5-7 illustrate another embodiment of a height adjustment mechanism300 useful in the present column assembly 100. Specifically, in thisembodiment, the height adjustment mechanism 300 includes a single rod302, which passes through an opening 124 a centered in the top of thebracket 128, as previously described, through interior space 102 a ofthe column body 102, the rod ending in a foot plate 303. At least onereinforcement anchor 114 is positioned within the column body 102, suchthat the single rod 302 passed through the center opening 114 a of thereinforcement anchor 114 or anchors located within the column body 102.A set screw 304 and collar 306 combination are positioned below the base124 of the bracket, the collar having a center opening 306 such that thesingle rod is vertically slidably within the collar. The set screw 304is configured for threaded engagement with a side opening 306 b withinthe collar 306. It should be noted the positioning of the set screw 304and collar 306 combination can be anywhere along the length of thecolumn body 102; however, higher placement of the set screw and collarwithin the column body may provide more convenient access for adjustmentonce the column assembly 100 is placed within a hole. Additionally, areinforcement structure, such as a reinforcement anchor 114, or otherform of reinforcement bar can be positioned below the set screw andcollar combination, for additional security. After the column assembly100 is placed within a hole, the height of the column assembly can bemade by sliding the assembly up and down along the rod 302, which has asmooth outer surface. Optionally, the outer surface of the rod 302 maybe textured for engagement with the set screw 304. Once the desiredheight is reached, the column assembly 100 can be locked into positionby tightening the set screw 304 against the rod 302. This embodiment ofthe height adjustment mechanism 300 provides easy manual adjustment andsetting of the height of the column assembly, eliminating the need foradditional tools and equipment.

FIGS. 8-9 show yet another embodiment of a height adjustment mechanism400 useful in the present column assembly 100. Similar to the heightadjustment mechanism 130 described above, this embodiment of the heightadjustment mechanism 400 is a three component assembly, including afirst rod 402, a hollow cylinder 404 disposed vertically within theinterior of the column body 102, and an extension rod 406. As shown inFIGS. 8 and 9, the cylinder 404, is positioned away from, and notconnected directly to the bottom or undersurface 124 a of the base 124of the bracket 128. In this embodiment, a threaded nut 403 is at the topof the cylinder 404, which is used for engagement with a threaded outersurface of the first rod 402, as previously described. Alternatively,rather than including a threaded nut 403 at the top of the cylinder 404,the interior or inner surface of the cylinder 404 could be threaded forengagement with the threaded surface of the first rod 402.

This height adjustment mechanism 400 functions in a similar manner toadjust the height of the column assembly 100 as the previously-describedheight adjustment mechanism 130. The first rod 402 passes through ancenter opening 124 b in the base 124, where it enters the interior spaceof the cylinder 404. With its foot plate 407 at ground level in a hole,the extension rod 406 passes upward through the bottom 106 of the columnbody 102, and into the interior space of the cylinder, where it meetswith the first rod 402. As the first rod 402 rotates and pushes againstthe extension rod 406, the vertical height of the column assembly 100can be adjusted up or down to the desired position. As previouslydescribed, any number and positioning of reinforcement anchors 114 areprovided within the interior 102 b of the column body 102.

The present height adjustable column assembly 100 is designed to replacethe standard wood, concrete, or combination of both, traditionally usedas foundation columns in post-frame or pole barn construction.Constructed from any suitable corrosion-resistant material, such asgalvanized steel powder coat or plated materials, the present heightadjustable column assembly 100 is light-weight (weighing less than 40pounds) making easily maneuverable and adjustable for placement withinan excavated hole 600, without the need to additional tools orequipment. However, and unlike traditional wooden posts, which can rotand potentially fail, the present column assembly 100 is not susceptibleto the elements or insect infestation, nor will the present columnassembly expand and contract due to freezing and thawing. Additionally,and unlike traditional precast concrete columns, which are heavy andhard to maneuver once set in place, the light-weight construction of thepresent column assembly 100 allows for easy placement and adjustability,particularly in view of any one of the height adjustment mechanismassemblies 130, 300, 400 described above. Concrete columns as well canbe susceptible to cracking and water damage, which can again jeopardizethe overall stability of a structure, and thus are not ideal for use asfoundation supports.

Installation of the present height adjustable column assembly 100 in theconstruction of a post-frame building 500 is significantly easier thantraditional foundation systems. Initially, a series of holes 600 are dugusing known methods (for example, manually or using an auger) to createthe intended perimeter of the building 500. A separate height adjustablecolumn assembly 100 is set, generally by hand by one or two persons,into each hole 600 (FIG. 2). Each height adjustable column assembly 100comes preassembled, and the pre-drilled holes 121 in various positionsalong the length of the arms 122 of the brackets 120, 128 make forsimple attachment of grade boards, planks or splash boards set into theside support brackets 126 of the column assembly. The present columnassembly 100 is much lighter than traditional wooden posts and concreteposts, making lifting and placing the column assemblies safer andeasier, as well as, reducing or even eliminating the need for heavymachinery to assist in transportation and installation. In fact, eachcolumn assembly 100 can be adjusted by one or two persons without therequirement for heavy equipment and with precision while upright, whicheliminates the need to correct wood post lengths on site. Additionally,another advantage of using the present adjustable column assembly 100 isthat post hole depths do not need to be exact, and the standard heightindustry variation of +/−3 inches is done away with. After theappropriate height adjustment is complete using the particular heightadjustment mechanism 130, 300, 400 described above, the excavated holes600 can be filled with concrete to set the adjustable foundation columnassemblies 100 in place to create the foundation.

As described, the adjustable column assembly 100 is used to create thefoundation for a structure, by acting as a base for attaching gradeboards and post frame columns. Although it is common to use wood gradeboards for creating the foundation of a structure, FIGS. 11-13illustrate an alternative connection bracket and grade board combinationdevice 700 that can be attached/used with any column 900, which providesdistinct advantages over use of traditional wood grade boards whenbuilding the foundation. FIG. 11 shows the connection bracket 710, whichis designed to engage a grade board 800, as shown in FIG. 12. Thebracket 710 includes a center section 711, an upper portion 712 and anopposing lower portion 714. The upper portion 712 comprises a firstsection 712 a angled outward from a top 711 a of the center section 711and a second vertical section 712 b connected to the first section 712a. The opposing lower portion 714 comprises a first section 714 aextending horizontally from a bottom 711 b of the center section 711 anda second vertical section 714 b connected to the first section 714 a.The upper portion 712 and opposing lower portion 714 are designed toengage and support a grade board 800, as shown in FIG. 12.

The grade board 800 itself is constructed from a galvanized steel, whichis coated with a proprietary coating (InterCoat®ChemGuard byChemcoaters, Gary, Ind.) to improve the corrosion resistance of thegalvanized steel. It should be understood that although the grade board800 is shown in a short length for illustration, the grade board can beprovided in any standard or customized foundation board lengths. Thegrade board 800 includes a first section 810 connected through a middlesecond 812 to an opposing second section 814, forming a substantiallyU-shaped configuration, which is complementary to the shape of theconnection bracket 710 such that the grade board engages the bracket(FIG. 12). The first section 810 and second section 814 each includes acenter, longitundinal ridge 816. Thus, the design of the center ridge816 of the grade board 800 provides an option to stack and engagemultiple grade boards one on top of the other, as shown in FIG. 13.Advantages of the connection bracket and grade board combination 700include: configuration of connection bracket 710 permits easy, secureinstallation of the grade board 800, without requiring special tools,while the coated, galvanized steel grade board is not subject todeterioration, rotting, cupping, warping, crowning or twisting,resulting in a true straight, long-lasting foundation for a structure.

The features and advantages offered by the present height adjustablecolumn assembly 100 mean that installation of the foundation column isquick, yet precise. Each column assembly 100 can be accurately put inplace quickly, with a typical installation of an entire foundation for apost-frame structure being completed in a single day. The speed andprecision of installation makes the height adjustable column assembly100 ideal for stub-ahead projects; crews can dig, set the columns andinstall the splashboard prior to concrete backfill. This is alsobeneficial to the new building owner because it allows subsurface work(plumbing, electrical, in-floor heat, etc.) to be complete and concreteflooring poured prior to the crew returning to build the building.

In short, the time savings in installation combined with the durabilityof foundations built using the present adjustable column assembly 100translate directly into improved safety, costs and labor savings whencompared to other traditional foundation methods. The lightweight natureof the present column assembly 100 means the columns can essentially beset in place by hand by one or two persons, reducing or eliminating theneed for tools and heavy equipment, making job sites safer and resultingin more efficient crews. Since column heights and overall leveling canbe easily adjusted on site, supporting structural wood columns canarrive pre-cut and ready for attachment to the foundation system.

Advantages of the present height adjustable column assembly 100 includethat it is invulnerable to the rot, decay and insect damage thattraditional wooden posts are susceptible to, nor will the presentfoundation column expand and contract due to freezing and thawing. Thesuperior strength of the galvanized steel foundation column of thepresent assembly 100 means that the structural foundation will nevertwist or warp, allowing foundations that utilize the present device andsystem to be more durable and well-protected against destructive naturalforces than the average post frame building foundation.

As an alternative to new construction of a building, oftentimes there isa need or desire to repair and reinforce existing post-frame structures,specifically the wood foundation columns found in many post-framestructures, barns and other buildings. Repair or reinforcement ispreferred in terms of time and costs over complete replacement of woodencolumns in many of these structures. Additionally, razing a structuremay not be an option if the structure has historical or family value.

As shown in FIGS. 14-17, an embodiment of a reinforcement device in theform of a multi-sided sleeve 200, is provided, which is useful forengagement with existing wooden columns 250 in post frame buildings. Asillustrated in FIGS. 14 and 15, the reinforcement sleeve 200 includes anelongated body 210 comprising a longitudinal center section 212integrally connected to a pair of opposing longitudinal legs 214 or sidepanels having a length equal to the center section. Each leg 214includes multiple angles or bends 216. It should be understood that theangles or bends can vary in number and degree, and are adjustable foraccommodating columns or posts of varying sizes. The resulting structureis a three-side configuration with an opening 218 that enables thesleeve to be adjusted and wrapped around three sides (the face and twosides) of an existing column 250 or post having a variety of shapes andsizes. Optionally, as shown in FIG. 15b , the sleeve 201 may include aslightly modified configuration, which is useful for corner or jambcolumns. In this corner sleeve 201, the side panels 202 include an outerlip 203 configured for meeting the walls of a structure at the corner ofthe structure.

The reinforcement sleeve 200 has an overall corrugated shape, includinga plurality of curved bends 216, folds or parallel and alternatingridges and grooves formed within the side panels 214 and the centersection 212. For example, and as shown in FIG. 14, in one embodiment,the center section 212 is includes a raised center 212 a. Additionally,each side panel 214 includes a raised portion 214 a in each panel. Theraised center 212 a and side panel raised portions 212 a, 214 a providethe sleeve 200 with the adjustability to fit any shape of existingcolumn 250, and lends strength to the sleeve. It should be understoodthat the raised portions 212 a and 214 a of the center section and sidepanels, respectively, can have any shape of bend, curve, ridges orgrooves, and thus the disclosure should not be limited to the embodimentshown.

As shown in FIGS. 15 and 15 a, the reinforcement sleeve 200 furtherincludes at least one uplift tab 222 positioned on one or both of theside panels 214, The uplift tab 222 includes a plurality of teeth 224(FIG. 15a ). When the reinforcement sleeve 200 is placed over theexisting wooden column 250, and driven down around the column with asuitable manual tool (i.e., hammer or maul), jack hammer, hydraulicdevice or another other suitable means for driving the sleeve into theground, the teeth 224 of the uplift tab 222 engage into the sides of thecolumn 250 (FIGS. 16 and 17). In this manner, the reinforcement sleeve200 is secured around the wooden column 250, and it cannot be removed.

The reinforcement sleeve 200 can be constructed from any suitablematerial, preferably steel, including galvanized steel for strength,longevity and corrosion-resistance. Additionally, the reinforcementsleeve 200 can have any length required for the particular project. Forexample, a sleeve 200 used for strengthening an existing column or postmay be shorter in length than a sleeve that will be used for extendingthe height of a structure. Once installed into the ground 230 around anexisting support column 250, the reinforcement sleeve 200 can be securedto the existing support column, using any manner of fastener includingnails, screws, bolts, etc., through fastener holes 220 on the sleeve.The reinforcement sleeve 200 acts to stiffen and reinforce the lowerportion of the wooden column 250 against lateral, uplift, and downwardpressures. Additionally, straps (not shown) may be used to furtherfasten the reinforcement sleeve 200 around the column 250 or post.

Installation of the reinforcement sleeve 200 may be completed with aspecialty hydraulic driving device, similar to an automatic jack hammer,which mechanically drives the sleeve into the ground around the targetcolumn 250. An advantage of using the hydraulic driver is that itreduces the amount of digging required to place the reinforcement device200 into position. Although a slight amount of digging may be requiredaround the base of the post or column to initially place thereinforcement device 200, the driver secures the reinforcement devicebelow grade using less time and manpower than traditionally required toplace a second securing post. It should be understood that in place ofthe described driver, the reinforcement sleeve can also be installedusing any suitable manual tool (i.e., hammer or maul), jack hammer, oranother other suitable means for driving the sleeve into the ground.

Wood columns used to construct post frame buildings tend to fail overtime due to dry rot and decay caused by microbial activity at the soilsurface and just below the surface. This creates a risk of columnfailure or building damage, which is a real problem for the buildingowner, and can be very expensive to repair. The present disclosure alsoincludes a system and method for reinforcing a column, post or othersupporting structure for a building using the reinforcement device 200.

The system and method for reinforcing and/or stabilizing a column 250 orpost includes the steps of initially digging a shallow hole 230 ortrench around the base of the target column 250. The reinforcementsleeve 200 is then positioned within the hole 230 and over the existingcolumn 250 from inside the building. Because of the corrugated shape ofthe reinforcement sleeve 200, the center section 212 and legs or sidepanels 214 of the sleeve cradle and contact the column at multiplecontact points as shown in FIG. 14. For example, as noted in the figure,the raised portions 212 a, 214 a of each of the center section and legsdo not directly contact the column 250. The corrugated shape of thereinforcement sleeve 200 provides strength and spacing needed to drivethe sleeve into position around the column. If the sleeve 200 fit tightagainst the column 250, it would be harder to drive the sleeve down intoposition.

Although a reinforcement sleeve 200 is described as an option forreinforcing an existing wooden column, there is an option to use theheight adjustable column assembly 100 described above in the repair of astructural column. Specifically, the existing column can be dug out ofthe ground and removed. The adjustable column assembly 100 would then bepositioned in the ground, completely replacing the wooden column.Because the adjustable column assembly is not susceptible to theelements, or insect infestation, it would provide a long-term solutionto maintaining the foundation of the existing building.

For decades, post frame buildings were built all across America thatwere designed to store equipment and machinery that was much smallerthan what is in use on today's modern farms. As a result, many of theseotherwise useful buildings are being removed to make room for newbuildings with higher interior clearances. However, there is often areason to save and restore existing buildings, including costs,historical value and sentimental value.

The present disclosure includes a system and method for raising theheight of an existing structure by up to 36″, thereby increasing theuseful interior space. The system and method for raising the height of astructure includes using the present reinforcement sleeve 200. Thereinforcement sleeve 200 can have any suitable length, for example up to12 feet long, which makes the reinforcement sleeve useful for raising anolder, shorter building to a newer height. Once the reinforcement sleeve200 is installed around an existing column 250 as previously described,the existing wood columns can be extended up to 36″, thereby increasingthe interior clearance and allowing the height needed for today's modernfarm equipment, construction equipment, or just to provide additionalinterior storage space within an existing structure.

The method of raising an existing structure begins with cutting anexisting column will both sides and on the face of the column. Thereinforcement sleeve 200 will be driven into the ground (using some formof a driver as described above), leaving a suitable portion of thesleeve above grade. The remaining portion of the column 250 would thenbe cut separating the column into two pieces. The building or structurewould be jacked up or lifted incrementally using known methods andequipment (i.e., jacks), until it reached the desired height. The gapfrom the lift would be filled with appropriate filler. A verticalfastener, such as a steel strap would be used to fasten and tie all thepieces together, including the sleeve 200, which would also be attachedto the column 250. After raising the structure to the desired height,any void left under the existing sidewall would be filled in withappropriate material, for example, a new steel wainscot.

It should be noted that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications may be madewithout departing from the spirit and scope of the present invention andwithout diminishing its attendant advantages. Further, referencesthroughout the specification to “the invention” are nonlimiting, and itshould be noted that claim limitations presented herein are not meant todescribe the invention as a whole. Moreover, the inventionillustratively disclosed herein suitably may be practiced in the absenceof any element which is not specifically disclosed herein.

We claim:
 1. A system for constructing and supporting a foundation for astructure, the system comprising: a supporting column for a structure; abracket secured to the supporting column; and, a grade board configuredfor engagement with the bracket.
 2. The system of claim 1, wherein thebracket comprises an upper portion, an opposing lower portion and acenter section positioned between and connecting the upper portion andthe lower portion.
 3. The system of claim 2, wherein the upper portioncomprises a first section angled outward from a top of the centersection and a second vertical section connected to the first section. 4.The system of claim 2, wherein the lower portion comprises a firstsection extending horizontally from a bottom of the center section and asecond vertical section connected to the first section.
 5. The system ofclaim 1 wherein the bracket is configured for securing the grade boardbetween the upper portion and the lower portion.
 6. The system of claim1, wherein grade board comprises a first section, a middle second and anopposing second section.
 7. The system of claim 6, wherein the firstsection is connected through the middle section to the second sectionforming a U-shaped configuration.
 8. The system of claim 6, wherein thefirst section of the grade board includes a center longitudinal ridge.9. The system of claim 6, wherein the second section of the grade boardincludes a center longitudinal ridge.
 10. The system of claim 8, whereinthe longitudinal ridge is configured for engagement with a correspondinglongitudinal ridge on a complementary grade board.
 11. The system ofclaim 10, wherein the engagement of the grade board with another gradeboard form a stacked structure for forming a foundation for a structure.12. A device for constructing a foundation for a structure, the devicecomprising a bracket; and, a grade board configured for engagement withthe bracket.
 13. The device of claim 12, wherein the bracket comprisesan upper portion, a center section and an opposing lower portion. 14.The device of claim 13, wherein the the bracket is configured forsecuring the grade board between the upper portion and the lowerportion.
 15. The device of claim 14, wherein the bracket is configuredfor securing more than one grade board between the upper portion and thelower portion.
 16. The device of claim 12, wherein the grade boardcomprises a first section connected through a middle section to a secondsection forming a U-shaped configuration.
 17. The device of claim 12wherein the grade board is configured for engagement of one grade boardwith a second grade board.
 18. The device of claim 17, wherein the gradeboard includes a ridge within the first section and the second section.19. The device of claim 17, wherein the ridge of one grade board isconfigured for engagement with the ridge of a second grade board. 20.The device of claim 17, wherein the engagement of the grade board withanother grade board form a stacked structure for forming a foundationfor a structure.